Part 2B - Removing the Subaru Wiring Harness

Article Summary

In this article you will learn the basic steps of how to extract the wiring harness from your donor Subaru car. Once again, this is a 1995 EJ22, but the process of harness removal is very similar to other year models. This step can seem challenging at times, but with patience, it is very feasible for a novice mechanic.

Lessons Learned

As you will see in the following steps, the crux of this removal process is removing the dash and structural member behind the dash. If you study the pictures below and find the correct bit for your screwdriver, life will be much easier. If not, you will find yourself like us prying the harness out. Another key step for removing the dash is to remove the bolts under the windshield from the outside of the car. If a wire connector is giving you problems, review the necessary connectors in the next article and if you feel confident that you don't need the connector, snip the wire and move on.

Time Needed

You will notice that this part of the Subaru conversion does not have many finite discrete steps. So, I decided not to time every detail of this process. I can tell you that it took Mick and I both about a day to remove. Therefore, conservitively speaking, it may take you about 3 days by yourself if you are a novice.

Tools You May Need

tin snips

screwdriver (philips and star shaped if possible to obtain) see pic below

socket set (metric)

Cro-bar (optional)

wire cutters

plastic bags to keep screws/bolts/clamps for later use

masking tape and marker

flashlight (for working under the dash)

Needle-nose pliers (for disconnecting connectors)

1st Stage: Take a Walk Around the Bay

Step 1: Make sure your battery is disconnected and your car is in a safe and static position to work on. Okay, now the first and easiest part is to begin freeing the wiring harness from the engine bay. The following pictures and captions will help explain.

1. No more bulky engine in the way. Time to extract our wiring harness and other goodies!

2. Here are your wiring harness components

3. Label your O2 sensors

4. Your O2 Sensor will be loose. Do not lose this.

5. You will not need the Subaru starter, but you will need the wires to it.

7. This wire you will find plugged into your Subie starter. Label and keep it.

8. You will begin removing the harness by unclipping or cutting the clips from the engine bay.

9. You will work your way around freeing the harness from the bay and you will come to this relay panel.

10. Cut the wires seen in this picture.

11. Cut these too. You will not need this panel of relays.

13. Scavenge all the coolant hose and clamps you can find before selling your donor car. It may be usefull for your new engine setup.

Step 2: Collect the necessary mechanical goodies and maybe some optional parts if you want to show off.

1. Keep your Subaru ignitor.

2. (Optional) This is your power steering pump. If you want the wheel to turn easy, check out the next couple slides.

3. First unscrew the cap and drain the hydraulic fluid. Properly contain and dispose this fluid.

4. Use two wrenches to separate the power steering hoses.

5. Say hello to your throttle cable. You will certainly need this. You will have to work inside the car to free the cable, but wait to do this later.

6. (Optional) Charcoal canister. Keep this.

7. Fuel filter. Keep this. It will work great in your Vanagon.

8. (Optional) If you are feeling fancy, remove your cruise control as seen here.

Stage 1.5: "Removing" the Driver Side Front Body Panel

We are quickly sailing our way to the cab of the car! This is a quick and mostly self-explanatory step. What I have not shown in these photos is cutting the rubber grommet that separates the engine bay from the area behind the front panel. This can be tedious, but take your time and figure out how to gently push/pull the harness through the engine bay wall as seen in the last photo in this stage.

1. Ahh...the driver side panel "removal"

1. I like to start with this bolt here.

1. Next.

1. You will start to find bolts in strange places.

1. What!? There is one here too? :)

1. Don't waste your time trying to get these bolts.

1. If you pull the panel back, you will see the harness travelling to the cab.

1. Cut the wires going to the radiator fan and headlights as I have done in the picture.

1. Ok, so I gave up trying to fully remove the panel and snaked the harness through to the cab.

Stage 2: In the Cab (Dash Removal)

Step 1: Drivers’ Side Footwell

Your main objective in this stage is to remove the dash. Therefore, remove any bolt or screw that you believe is holding the dash to the car. There will also be wire connectors to disconnect. If you have trouble with disconnecting a connector and are certain that it is not a needed connector, then cut the wire and don’t worry. In case you are wrong and the connector is needed, go ahead and cut/keep the connector for good measure. There are quite a few wires that go to the side doors. Cut these wires. They are not necessary.

1. Quickly remove the panel shown to expose your wires.

"Helpful Hints"

2. This is your OBD2 diagnostics plug.

3. Remove it from the housing and label the connector...you will need this one later.

4. You will need to drop the steering wheel by removing a few bolts like the one shown. Be careful not to put your face in front of the wheel. The airbag should not deploy, I just don't trust it.

5. If you look back up under the dash, you should be able to see the main bundle of wires that you will soon remove.

6. By each of the front doors, you will find bolts hidden under these tabs. Remove the bolts.

7. Remove your shifter shroud.

8. This is when you will learn TMI about your previous owner of the car.

9. Keep unscrewing and unbolting anything that may help the dash removal.

10. Let's remove the stereo.

11. Can you spot me in this picture?

12. ...

13. Remove the A/C vents and remove the bolts found there.

Step2: Passenger Side Footwell

Go around to the passenger side and begin removing the numerous bolts. After you have removed the all the bolts you could find and the ones shown on the following slides, you may have to shake the dash and figure out what is keeping it from being removed. Search and find all the snags and you will be ready for the next stage. The key bolts are the ones at the base of the windshield.

1. Strip away the floor matt and carpet.

2. And you will find the brain: OBD2

3. Unplug and store the OBD2 Computer in a safe place.

4. Remove the glove compartment.

5. Remove this too.

6. After removing the piece shown, you will find a row of bolts along the windshield.

7. Go to the outside of the car and remove the row of bolts near the base of the windshield.

8. While you are outside the car, find the harness grommet going to the dash and push these wires partially through toward the cab.

9. If you have removed all of the bolts, you will now be able to remove the dash.

10. Only to find your next hurdle: The structural bar which is blocking you from freeing the wiring harness.

Stage 3: Dislodging the Structural Bar and Removing the Harness

This is the fun part. This step is pretty self explanatory. Use safe methods of prying the structural bar loose. You may need a buddy to help you with this.

1. Begin unbolting the bar from the passenger side.

2. You will find that you cannot fully remove the bar without removing the Airbag Control Unit.

3. Unfortunately, our toolbag did not come with this type of screwdriver head.

4. So, we used a pry-bar to dislodge the structural bar from the passenger side. This gave us enough room to access the harness.

5. Here is your harness.

6. You will have to unscrew the white plastic wire housings from the car.

7. Go around to the outside and push your harness through toward the cab.

8. At this point there is no explaining to do.

9. Take a picture like this. Make sure your pants stay up.

Conclusion

I learned to be patient and take my time on this step in the conversion process. Finding all of the bolts that keep the dash in place may be challenging but you will succeed. Have fun and enjoy wrenching!